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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Observation of shock-front separation in multi-ion-species collisional plasma shocks

We observe shock-front separation and species-dependent shock widths in multi-ion-species collisional plasma shocks, which are produced by obliquely merging plasma jets of a He/Ar mixture (97% He and 3% Ar by initial number density) on the plasma liner experiment. Visible plasma emission near the He-I 587.6-nm and Ar-II 476.5–514.5-nm lines is simultaneously recorded by splitting a single visible image of the shock into two different fast-framing cameras with different narrow bandpass filters (589 ± 5 nm for observing the He-I line and 500 ± 25 nm for the Ar-II lines). For conditions in these experiments (pre-shock ion and electron densities ≈5×10 14 cm –3 , ion and electron temperatures of ≈2.2 eV, and relative plasma-merging speed of 22 km/s), the observationally inferred magnitude of He/Ar shock-front separation and the shock widths themselves are <1 cm, which correspond to ~50 post-shock thermal ion–ion mean free paths. These experimental length scales are in reasonable qualitative and quantitative agreement with results from 1D multi-fluid simulations using the CHICAGO code. However, we note there are differences between the experimentally inferred and simulation-predicted ionization states and line emission intensities, particularly in the post-shock region. Overall, the experimental and simulation results are consistent with theoretical predictions that the lighter He ions diffuse farther ahead within the overall shock front than the heavier Ar ions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Low-Temperature Plasma Assisted Kinetics Study of Ethanol

Abstract: Non- equilibrium plasma assisted kinetics of ethanol at 0.5 atm over a temperature range of 523-1203 K were studied at stoichiometric conditions by using a plasma flow reactor (PFR). The effects of plasma chemistry on fuel and its influence on neutral chemistry is decoupled with both experimental and modelling efforts. Enhanced reactivity was observed experimentally in both plasma-assisted oxidation and pyrolysis cases with fuel consumption beginning at temperatures as low as 523 K. Absolute fuel consumption was observed at temperatures nearly 200 K earlier than pure thermal reactions highlighting the effectiveness of non-equilibrium plasma to promote reactivity. Modelling results illustrated the effect of electron impact reactions towards accelerating fuel consumption and promoting low temperature chemistry by generating excited state N2 and reactive O and OH radicals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Understanding the Surface Structure and Catalytic Activity of SnO x /Au(111) Inverse Catalysts for CO 2 and H 2 Activation

Carbon dioxide hydrogenation is a promising approach for the reduction of greenhouse gas pollution via the production of fuels and high-value chemicals utilizing C1 chemistry. In this process, the activation of nonpolar molecules, CO 2 and H 2 , at mild conditions is challenging. In this study, we report a well-defined inverse SnO x /Au(111) catalyst that shows the ability to activate both CO 2 and H 2 at room temperature. Scanning tunneling microscopy (STM) and ambient pressure X-ray photoemission spectroscopy (AP-XPS) are combined to understand the surface structure, growth mode, chemical state, and activity of SnO x /Au(111) surfaces. Nanostructures of SnO x at the sub-monolayer level were prepared by depositing Sn on Au(111) followed by O 2 oxidation. For the as-prepared SnO x /Au(111), two-dimensionally formed SnO x thin films on a Au(111) substrate were observed with STM of two different moieties, discernible based on their height: clusters (~0.4 Å) and nanoparticles (NPs, 1–2.5 Å), which are assigned to Sn–Au alloys and SnO x , respectively, in corroboration with XPS analysis. Furthermore, SnO x /Au(111) was annealed under UHV to test its thermal stability. Upon annealing at 400–600 K, a disappearance of SnO x NPs and reappearance of highly dispersed Sn clusters were clearly noticeable from the STM and XPS results, identifying the thermal decomposition of SnO x and subsequent formation of Sn–Au alloys on the surface due to the recombination of Sn clusters with Au. We investigated the reactivity of the SnO x /Au(111) surfaces toward CH 4 , CO 2 , and H 2 . The SnO x /Au(111) surfaces have excellent CO 2 and H 2 activation abilities even at room temperature with negligible reactivity for methane activation. Our AP-XPS results show that H 2 can be activated on the SnO x NPs by the reduction to Sn. For CO 2 , the activation and further dissociation are identified by a reoxidation of Sn with newly formed Sn–O bonds and the formation of surface carbon. Therefore, we propose that SnO x is a potential catalyst or additive to achieve CO 2 hydrogenation under mild conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Reducing Methane Emissions with an Engine Fuel Reformer

Southwest Research Institute (SwRI) designed and demonstrated a compact, plasma-based fuel reformer designed to reduce methane leaks from natural-gas engines used in pipeline compression and industrial power applications. The system uses pulsed electrical discharges to convert a small portion of methane (CH4) into hydrogen (H2) and light hydrocarbons, promoting more complete combustion and reducing unburned methane in the exhaust. The reformer was evaluated through bench-scale testing, high-flow facility testing, and engine-integration testing on representative low-speed and high-speed natural-gas engines. Measured methane-leak reductions ranged from 1 to 27 percent, depending on engine type and operating condition, while reformer energy consumption remained below one percent of total engine output. Design refinements addressed thermal and electrical challenges, resulting in reliable operation with minimal impact on engine control systems. The project achieved all performance objectives within budget and schedule, produced a patentable pulsed-power system design, and established a scalable, energy-efficient pathway for mitigating methane leaks from existing natural-gas engine infrastructure.

03 NATURAL GAS↗
DOE OSTI2021

Studying drought-induced forest mortality using high spatiotemporal resolution evapotranspiration data from thermal satellite imaging

Drought can have pervasive and wide-spread impacts to forest health, as evidenced in several severe events occurring over the recent decades. Extensive forest die-off due to drought can impair the ecological functioning of forests, impacting habitat, water yield and quality from forested lands, and altering forest fire dynamics and intensity. Satellite remote sensing provides an effective means for detecting and monitoring spatial patterns of forest mortality over large areas, exploiting free and open long-term image archives available at a range in spatial and temporal resolutions. While remotely sensed surface reflectances and vegetation indices have been widely used to study optical response of forest canopies to drought events, retrievals of evapotranspiration (ET) derived from thermal satellite imagery – particularly at resolutions approaching crown scale - can provide insights into cumulative tree stresses that can incite disease and trigger mortality. In this study, we applied a multi-sensor satellite data fusion approach to estimate daily 30-m resolution ET and an associated Evaporative Stress Index (ESI) to study drought-induced mortality in a temperate forest at the Missouri Ozark AmeriFlux (MOFLUX) site, located in the central United States. The study covered the period from 2010 to 2014, including an exceptional drought year of 2012. Modeled ET agreed well with eddy flux measurements from the MOFLUX tower, with average monthly relative errors of 15%. Plot-scale ESI, describing temporal anomalies in the ratio of actual-to-reference ET, was used as an index of relative forest health to investigate relationships between forest mortality and drought severity. ESI showed good agreement with observed predawn leaf water potential, especially during the drought year. Furthermore, plot-scale ESI was also correlated with the subsequent year's tree mortality, suggesting the importance of considering the forest health condition prior to drought when studying drought-induced forest impacts. This study demonstrates the utility of multi-year ET remote sensing data at the stand or plot scale as an indicator of forest health and as a predictor of future mortality due to drought.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Rapid Polyolefin Plastic Hydrogenolysis Mediated by Single-Site Heterogeneous Electrophilic/Cationic Organo-group IV Catalysts

A homologous series of cationic electrophilic group IV metal hydrides (M = Ti, Zr, Hf) created by chemisorption of the corresponding MNp 4 precursors on highly Brønsted acidic sulfated alumina (AlS) to yield loosely coordinated surface AlS/MNp 2 (Np = neopentyl) species are systematically characterized by ICP, EXAFS/XANES, DRIFTS, and solid-state high-resolution multidimensional NMR spectroscopy (SSNMR), as well as by energy span DFT computation. With effective stirring, these complexes readily undergo reaction with H 2 to yield AlS/M(alkyl)H species, which are highly active for the hydrogenolysis of diverse commercial polyethylenes, α-olefin-ethylene copolymers, isotactic polypropylene, and postconsumer polyolefins including high-density polyethylenes, yielding medium and small linear and branched hydrocarbons at turnover frequencies as high as 36,300 h –1 at 200 °C/17 atm H 2 for M = Zr. For given polyolefin and reaction conditions, turnover frequencies scale approximately as M = Zr > Hf > Ti, whereas catalyst thermal stability scales approximately as M = Hf ≈ Zr > Ti, and these trends are qualitatively understandable from the DFT analysis. These catalytic results reveal that the AlS/Hf(R)H-mediated hydrogenolysis favors wax-like and liquid products, whereas the AlS/Zr(R)H-mediated hydrogenolysis can be tuned between gases and liquids. Finally, DFT analysis identifies β-alkyl elimination as the turnover-limiting C–C scission process, which is particularly facile in these cationic d 0 complexes but not so in the neutrally charged analogues.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Chemical beneficiation of cobaltiferous pyrite: a thermodynamic and parametric study

Despite ongoing efforts to identify substitute materials, cobalt remains indispensable for the production of rechargeable batteries essential to the global energy transition. Currently, most cobalt is sourced as a by-product of nickel and copper extraction from politically and ethically unstable regions. To address this vulnerability, certain primary cobalt deposits—where cobalt occurs within the crystal lattice of pyrite (FeS 2 )—have been identified as potential alternatives. Nonetheless, conventional beneficiation methods have proven largely ineffective for the potential processing of these minerals. This study investigated the thermal decomposition of cobaltiferous pyrite contained in flotation concentrates as a subsequent chemical beneficiation stage aimed at (i) selectively removing sulfur to further increase cobalt grades and (ii) producing a ferromagnetic product suitable for downstream magnetic separation. A thermodynamic analysis was first conducted to evaluate the feasibility of the decomposition reactions and the temperature-dependent evolution of sulfur species. A parametric experimental study then assessed the influence of temperature, residence time, and gas flow rate under N 2 and CO 2 atmospheres. Under the most favorable experimental conditions tested (650 °C, 15 min), cobalt grades increased by up to 15% with negligible cobalt losses and the co-production of high-purity sulfur (>95%). Magnetic separation of the resulting calcine yielded a final concentrate containing 2.09% cobalt at 82.5% recovery, representing a 16–74% improvement over previous baseline studies on similar feedstocks.

Beneficiation↗
DOE OSTI2026

Low Temperature Tantalum Electrodeposition: Enabling Next Generation Coatings

This project aimed to identify the ligand and solvation conditions necessary for the electrodeposition of refractory metals from low-temperature organic electrolytes. Tantalum (Ta) was chosen as a specific exemplar for programmatic purposes. It was hoped that a deeper understanding of these relationships could facilitate the innovative application of refractory metal coatings on thermally sensitive and geometrically intricate components used in extreme environments related to energy generation and storage, nuclear deterrence, aerospace, defense, and beyond.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Resource assessment of ocean thermal energy conversion in Puerto Rico and U.S. Virgin Islands

Island communities often struggle to establish and maintain traditional electric grids and are therefore heavily reliant on costly imported fossil fuels. In the case of Puerto Rico, these challenges are enhanced by extreme weather and other natural hazards that threaten the local electricity generation and transmission infrastructure. Ocean thermal energy conversion (OTEC) could play an important role in establishing a more resilient electrical grid in the region. Here, in this study, a detailed analysis is conducted to characterize the ocean thermal resource and power potential of OTEC in Puerto Rico based on a 14-year dataset of modeled ocean temperature. The assessment considers seasonal and interannual variability in the region's thermal resource and examines the operational limitations associated with minimal thermal gradients required to run a typical OTEC heat engine. Notably, the local thermal resource is found to be sensitive to El Niño-Southern Oscillation (ENSO) climate patterns, with La Niña conditions linked to greater OTEC power availability. Seven areas of opportunity are identified based on their resource potential and proximity to existing electrical distribution lines, including two that could benefit the nearby U.S. Virgin Islands. The greatest OTEC power potential is observed to the south of the main island of Puerto Rico in the Caribbean Sea with an estimated capacity of 138 MW for a plant pumping cold water from a depth of 1,000 m, or the equivalent amount of electricity required to power 219,000 households.

OTEC↗
DOE OSTI2023

Fluoride-Cooled High-Temperature Pebble-Bed Reactor Reference Plant Model

In this report we present work performed in Fiscal Year 2022 that demonstrates the modeling and simulation of a fully coupled neutronics thermal hydraulics reference plant model for a fluoride-cooled high-temperature pebble-bed reactor. The multiphysics model is developed on the Nuclear Regulatory Commission’s Comprehensive Reactor Analysis Bundle (BlueCRAB) available on the Idaho National Laboratory’s high-performance computer, which natively and seamlessly couples Griffin, Pronghorn, and the BISON Multiphysics Object-Oriented Simulation Environment based applications. Griffin provides reactor physics capabilities, including depletion to the equilibrium core, k-eigenvalue, adjoint, and transient. The unique direct equilibrium core capability in Griffin is based on a streamline methodology to spatially deplete the pebbles into burnup groups. Pronghorn solves the porous medium equations for the fluid regions and conduction in the solid regions and incorporates a fluidic diode model to simulate the transition from forced to natural convection during accident scenarios. MOOSE modules solves thermal conduction problems for the pebbles and tristructural isotropic in the pebble-bed core, thus providing the fuel and moderator spatial fields for each pebble burnup group. The neutronics feedback relies primarily on fuel, moderator, and reflector temperatures as as well as the FLiBe salt density. Here, we present results for the uncoupled equilibrium core and perform comparisons to equivalent Monte Carlo models. The power distributions and kinetic parameters obtained with Griffin are consistent with those computed with Griffin. We demonstrate a noticeable improvement with the use of discrete ordinates method (SN) transport. The coupled steady-state equilibrium core provides the initial condition for two time-dependent problems: a control rod withdrawal event and an unprotected loss of flow event. In both cases, the reactor design is self-stabilizing and the solutions are consistent with the expected physics. Although this model is prototypical regarding BlueCRAB’s capabilities, its results are consistent with published work by Kairos Power and other research entities. Significant improvements to the model are planned in future work.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Advanced Manufacturing of Thermal Protection System Tiles for Space Plane Atmospheric Reentry

Thermal protection systems (TPS) constitute a major material, engineering, and manufacturing challenge for space access. Atmospheric re-entry generates very high heats and requires advanced materials to withstand such conditions. Combining the required materials and integrating them into the vehicle is a major engineering undertaking that often must use creative designs to accommodate the selected materials and systems. Likewise, the manufacture of TPS is costly and challenging; it requires a combination of materials in a range of complex and unique shapes with specialized process conditions. Compounding these challenges, for harsh re-entry profiles or on high heat flux regions of the vehicle, even state of the art TPS is effectively single use and thereby creating a strong economic incentive to improve the TPS materials, integration, and manufacture. This work focuses on the use of ceramic modifications to TPS materials thereby allowing multi flight capability.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Multi-objective optimization of peel and shear strengths in ultrasonic metal welding using machine learning-based response surface methodology

Ultrasonic metal welding (UMW) is a solid-state joining technique with varied industrial applications. Despite of its numerous advantages, UMW has a relative narrow operating window and is sensitive to variations in process conditions. As such, it is imperative to quantitatively characterize the influence of welding parameters on the resulting joint quality. The quantification model can be subsequently used to optimize the parameters. Conventional response surface methodology (RSM) usually employs linear or polynomial models, which may not be able to capture the intricate, nonlinear input-output relationships in UMW. Furthermore, some UMW applications call for simultaneous optimization of multiple quality indices such as peel strength, shear strength, electrical conductivity, and thermal conductivity. To address these challenges, this paper develops a machine learning (ML)-based RSM to model the input-output relationships in UMW and jointly optimize two quality indices, namely, peel and shear strengths. The performance of various ML methods including spline regression, Gaussian process regression (GPR), support vector regression (SVR), and conventional polynomial regression models with different orders is compared. A case study using experimental data shows that GPR with radial basis function (RBF) kernel and SVR with RBF kernel achieve the best prediction accuracy. The obtained response surface models are then used to optimize a compound joint strength indicator that is defined as the average of normalized shear and peel strengths. In addition, the case study reveals different patterns in the response surfaces of shear and peel strengths, which has not been systematically studied in the literature. While developed for the UMW application, the method can be extended to other manufacturing processes.

42 ENGINEERING↗
DOE OSTI2026

Superstructure Optimization of Waste Plastic Pyrolysis, Integrating Thermal, Catalytic, and Plasma Technologies with Machine Learning

Global plastic waste generation exceeds 430 million tonnes per year, yet fewer than 9% are recycled in the United States. Pyrolysis offers a chemical recycling route at scale, but existing techno-economic and life cycle assessments fix product yields to single pure polymers, producing economic and environmental outputs that break down when the feed composition changes. Here, we present a superstructure optimization framework that addresses this by embedding a composition-aware random forest yield predictor, trained on 566 pyrolysis experiments, within a full-scale process simulation. Product distributions update automatically as feed allocation shifts across four reactor chemistries: conventional thermal, catalytic (HZSM-5), thermal oxo-degradation, and nonequilibrium CO2 plasma. The optimal superstructure achieves minimum selling prices of −0.56 to −0.76/kg feed and global warming potentials of −0.276 to −0.322 kg CO2-eq/kg feed across four commodity price scenarios, confirming profitable, carbon-negative operation without tipping fees. Carbon abatement costs of $\$$0.46 to $\$$1.25/kg CO2-eq are competitive with direct air capture. Sensitivity analysis shows that the catalytic-plasma split fraction is the single largest driver of both economic and climate performance, while hydrocracking allocation in the wax upgrading stage is emission-neutral across the full variable range. Mixed plastic waste streams, evaluated as composition-variable feedstocks rather than pure resins, are profitable and carbon-negative across realistic market conditions. These results give a quantitative basis for reactor selection, circular economy investment, and policy design targeting chemical recycling on a large scale.

Life cycle assessment↗
DOE OSTI2025

Characterizing and modeling the mechanical behavior of an anion exchange membrane for carbon capture applications

A new direct air capture (DAC) technology uses a moisture swing (MS) process with anion exchange membranes, potentially offering a more energy-efficient way to remove CO₂ from the air. In this MS process, the membrane absorbs CO₂ as it dries and releases it when water is added. Understanding the mechanical behavior of these membranes is essential for improving the design and efficiency of DAC systems and prolonging sorbent lifetime. This study tested one anion exchange membrane, Fumasep’s FAA-3, under mechanical loading and various temperature and humidity conditions to measure its swelling, stiffness, strength, plastic deformation, and stress relaxation. Experimental results were used to identify a mechanical model for FAA-3 that can be used to predict the material’s nonlinear viscous behavior under various loads and environments. Unlike prior studies that assumed linear elastic behavior, this work incorporates humidity-dependent swelling, thermal expansion, and nonlinear viscoelasticity of FAA-3 in both the experiments and the model.

Direct air capture↗
DOE OSTI2025

Experimental evidence of non-equilibrium phase separation in supercritical fluids

Supercritical fluids (SCFs), widely utilized in many industries, have long been regarded as homogeneous single-phase media. Recent simulation studies identified different phases (more gas-like or liquid-like) in SCFs at equilibrium, expanding the previous notion but still not addressing non-equilibrium properties of SCFs. Here we reveal the existence of long-lived liquid-like clusters in non-equilibrium SCFs by time-resolved small-angle neutron scattering measurements. Since SCFs in industrial applications frequently operate under dynamic, non-equilibrium conditions rather than strict thermodynamic equilibrium, our findings offer crucial information for improving the use of SCFs in industrial settings, like semiconductor cleaning and plant thermal-hydraulic engineering.

Lee, Juho [Pohang Univ. of Science and Technology ↗
DOE OSTI2024

Mist

Determining the appropriate material data is often a bottleneck for performing calculations/simulations of industrial/experimental processes and resulting material structures and properties. Beyond the time it takes to find the appropriate values in the literature, many judgement calls are involved in choosing the values. These judgement calls can lead to inconsistencies between steps in research workflow, where different material parameter values are used. Mist solves this problem by providing a mechanism to store, share, and use material information in convenient human-readable and machine-readable formats. Mist has an extensible ontology for defining a wide variety of material information, currently focused on metal alloy applications. Examples include: alloy composition, density, liquidus temperature, and the coefficient of thermal expansion. Mist converts between standardized machine-readable data formats (e.g. JSON), specialized input format for simulation tools, and human-readable documents (e.g. LaTeX, Markdown). For parameters defined by an equation (e.g. a polynomial function) or a list of tabulated values, Mist can evaluate parameter values at requested conditions. Mist also provides an API for direct usage of the Mist data structures in calculations, if supported.

DeWitt, Stephen [Oak Ridge National Laboratory (OR↗
DOE OSTI2025

Next generation retrofit wall panels with integrated vacuum insulation panels

Approximately two-thirds of residential buildings in the United States were constructed before the Department of Energy established energy conservation measures. These buildings present major opportunities for improving energy efficiency, though retrofitting them remains technically and economically challenging. This study presents the development and the durability evaluation of an innovative retrofit panel system that integrates vacuum insulation panels (VIP) with a nail-base panel (called a retrofit insulated panel) to enhance thermal performance with minimal disruption to occupants and without altering standard nail-based panel installation practices. Hygrothermal simulations were conducted to assess the moisture behavior of wall assemblies before and after retrofit installation under varying water vapor control strategies and climate conditions. Results indicate that, with appropriate moisture control strategy, the retrofit system effectively prevents moisture accumulation, keeping mold index values and relative humidity levels below critical thresholds. Additionally, Guarded Hot Box testing was performed to compute the effective R-value of the panel under different coverage areas that demonstrates its effectiveness in enhancing both thermal and moisture performance in existing residential buildings.

Iffa, Emishaw [ORNL]↗
DOE OSTI2026

Robust dynamic operation of high temperature electrolysis solid oxide cells

Here, this study evaluates the durability of Ni/YSZ-supported SOECs under dynamic operating conditions relevant to real-world applications. Systematic tests were conducted to assess cell performance under steam cycling (3 to 75% humidified H 2 ), mode cycling between SOFC and SOEC operation, thermal cycling (150 to 750 °C at OCV, and 600 to 800 °C at 1.3V), and redox cycling (between 50% humidified H 2 and 50% humidified N 2 ). Steam cycling, mode cycling, and thermal cycling at OCV do not significantly accelerate performance degradation. Thermal cycling at 1.3V caused minimal damage within 600 to 800 °C. Full redox cycling (multi-hour oxidation holds) induced cell structural failure, while partial redox cycling (0.5 h holds) was tolerated. Extensive characterization revealed some material evolution, namely Sr and Co secondary phase formation, within the oxygen electrode due to La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3-δ instability, especially for steam cycling and mode cycling. Minimal changes were identified within the Ni-YSZ fuel electrodes. These findings provide critical insights into SOEC reliability under dynamic conditions, supporting their application in dynamic or intermittent energy systems.

08 HYDROGEN↗